Variable Pole System for Electric Motors

This application is a continuation of U.S. Non-Provisional patent application Ser. No. 18/671,788, filed May 22, 2024. Moreover, any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.

The present disclosure relates generally to electric motors, and in particular, to electric motor having variable poles.

Electric motors have a large number of different applications, including automotive, drones, aerospace, rovers, among many others. Electric motors can efficiently convert electrical energy into mechanical energy. Many electric motors generate torque by applying an electric current to a wire winding which interacts with a magnetic field.

The innovations described in the claims each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of the claims, some prominent features of this disclosure will now be briefly described.

One aspect of this disclosure is an electric motor including: a stator including a plurality of magnetic conductive wires, the magnetic conductive wires configured to form a plurality of poles; a rotor configured to rotate in response to a magnetic field generated by the plurality of poles; and an electronic control module electrically coupled to the magnetic conductive wires, the electronic control module configured to adjust a configuration of the plurality of poles.

In some embodiments, the electronic control module is further configured to adjust a number of poles of the plurality of poles.

In some embodiments, the electronic control module includes: an electronic switch electrically coupled to each of the magnetic conductive wires; and a controller configured to control the electronic switch to adjust the configuration of the plurality of poles.

In some embodiments, each of the magnetic conductive wires has two connectors; the electronic switch is electrically coupled to each of the two connectors; and the electronic switch is configured to connect the magnetic conductive wires together to adjust a number of poles of the plurality of poles.

In some embodiments, the electric motor further includes a plurality of electrical wires configured to electrically connect each of the two connectors to the electronic switch; and a plurality of electrical cables, each electrical cable of the plurality of electrical cables including a subset of the plurality of electrical wires.

In some embodiments, the electronic control module is further configured to: connect the magnetic conductive wires to form a plurality of separate paths, each path of the plurality of separate paths being connected between a first voltage and a second voltage provided by the electronic control module.

In some embodiments, the electric control module is further configured to: connect the magnetic conductive wires such that each path of the plurality of paths is interleaved with at least two adjacent magnetic conductive wires of the magnetic conductive wires that have a same polarity.

In some embodiments, the electronic control module is further configured to: receive an input indicative of a requested torque of the electric motor, wherein adjusting the configuration of the plurality of poles includes changing a number of poles of the plurality of poles to increase an efficiency of the electric motor for the requested torque.

In some embodiments, the electronic control module is further configured to: determining that the requested torque is outside of a current band of efficiency of the electric motor associated with the number of poles of the plurality of poles, wherein adjusting the configuration of the plurality of poles is in response to determining that the requested torque is outside of the current band of efficiency.

In some embodiments, the rotor includes a squirrel cage configured to provide a static magnetic field, the plurality of magnetic conductive wires are configured to be connected to an alternating current power source to produce the magnetic field as a rotating magnetic field, and interaction between the rotating magnetic field and the static magnetic field results in a torque in the rotor.

In some embodiments, the electric motor further includes one or more sensors configured to monitor a parameter of the electric motor, wherein adjusting the configuration of the plurality of poles is based at least in part on the monitored parameter of the electric motor.

Another aspect is a method of controlling an electric motor, including: receiving, at an electronic control module of the electric motor, a control signal; adjusting, using the electronic control module, a configuration of a plurality of poles of a stator of the electric motor based on the control signal, the stator including a plurality of magnetic conductive wires configured to form the plurality of poles; and providing an alternating current power source to the plurality of magnetic conductive wires to generate a magnetic field that causes a rotor of the electric motor to produce torque.

In some embodiments, adjusting the configuration of the plurality of poles includes adjust a number of poles of the plurality of poles.

In some embodiments, the method further includes: coupling an electronic switch of the electric control module to each wire of the plurality of magnetic conductive wires; and controlling, using a controller of the electric control module, the electronic switch to adjust the configuration of the plurality of poles.

In some embodiments, each wire of the plurality of magnetic conductive wires has two connectors; the electronic switch is electrically coupled to each of the two connectors; and the method further includes connecting, using the electronic switch, the plurality of magnetic conductive wires together to adjust a number of poles of the plurality of poles.

In some embodiments, the method further includes connecting, using the electronic control module, the plurality of magnetic conductive wires to form a plurality of separate paths; and electrically connecting each path of the plurality of separate paths between a first voltage and a second voltage provided by the electronic control module.

In some embodiments, the method further includes connecting, using the electronic control module, the plurality of magnetic conductive wires such that each path is interleaved with at least two adjacent magnetic conductive wires of the plurality of magnetic conductive wires that have a same polarity.

In some embodiments, the method further includes receiving, at the electronic control module, an input indicative of a requested torque of the electric motor; and adjusting, using the electronic control module, a number of poles of the plurality of poles to increase an efficiency of the electric motor for the requested torque.

In some embodiments, the method further includes determining, using the electronic control module, that the requested torque is outside of a current band of efficiency of the electric motor associated with the number of poles, wherein adjusting the number of poles is in response to determining that the requested torque is outside of the current band of efficiency.

In some embodiments, the method further includes monitoring, using one or more sensors, a parameter of the electric motor; and wherein adjusting the configuration of the plurality of poles is at least in part based on the monitored parameter.

Electric motors are useful in a large variety of industries, including, for example: automotive and transportation, maritime industry, power generation, manufacturing and heavy industry, heating, ventilation, and air conditioning (HVAC) and refrigeration, mining industry, construction, agriculture, water and wastewater treatment, aerospace and drone industry, home appliances and consumer electronics, rail sector, etc. Each industry may have many different applications for electric motors, examples of which are provided below.

In the automotive and transportation industries, electric motors can be used in electric, hybrid, and hydrogen vehicles; heavy and freight vehicles; public transport systems' and urban mobility vehicles.

Within the maritime Industry, example applications include: in ship propulsion systems, port operations (cranes, forklifts, etc.), and underwater vehicles, where precise speed control and energy efficiency are desirable.

Example uses of electric motors in power generation include: integration with renewable energy sources such as wind, hydroelectric, wave, among others, where the ability to adapt generator speed can improve energy production.

In manufacturing and heavy industry, example applications include: production machinery that requires precise speed and torque control, automation and robotics systems, and material transport.

For HVAC and refrigeration, electric motors can be used in: fans, blowers, and pumps, where energy efficiency and flow control can be important.

Electric motors are also used in the mining industry, for example, in: drilling and excavation equipment, and material transport systems, where robustness and adaptability to variable conditions can be important.

For construction, example applications include: cranes, lifts, and paving and compaction machinery, where precise control and adaptability to different tasks can improve efficiency and safety.

Example uses of electric motors in agriculture include: agricultural machinery and irrigation systems, where efficiency and adaptability can improve productivity and resource use.

Electric motors are also used in water and wastewater treatment, including in: pumps and aeration systems, seeking energy efficiency and adaptability to flow and demand variations.

Within aerospace and drone industry, example uses for electric motors include: unmanned aerial vehicles and auxiliary systems in aircraft, where efficiency and precise control can be important.

For home appliances and consumer electronics, electric motors can be used in applications where energy efficiency and speed control enhance performance and user experience.

In the rail sector, examples use cases for electric motors include: trains and signaling systems, where energy efficiency and speed control can be important for operation and safety.

While there are many advantages to using electric motors in many different applications, traditional electric motors may have certain challenges. One drawback to traditional electric motors is in operational flexibility. For example, a common challenge with traditional electric motors is their limited ability to adapt to different speeds and torque requirements without compromising efficiency.

Another drawback to traditional electric motors relates to energy efficiency. Many electric motors operate sub-optimally when outside of their specific design conditions, resulting in unnecessarily high energy consumption or inefficiency.

Traditional electric motors may also have an overly complex system design and high costs. Traditional electric motors may rely on external systems for speed and torque control, which adds complexity, costs, and potential failure points to the overall system.

Still another challenge for traditional electric motors relates to dynamic response and control. It is desirable to improve the electric motor's responsiveness and control to rapid changes in load demand.

It can also be difficult to adapt traditional electric motors to new applications. It is desirable to quickly adapt electric motors to new applications or changes in the specifications of an existing application, which is limited with traditional designs.

Traditional electric motors may also be difficult to maintain and have limited durability. It is also desirable to reduce the frequency and complexity of maintenance, as well as extending the electric motor's lifespan.

Another challenge is the integration of advanced technologies with electric motors. For example, in many circumstances it is desirable to incorporate advancements in power electronics, digital control, and intelligent algorithms to enhance motor functionality and performance.

Aspects of this disclosure address some or all of the above challenges. In particular, aspects of this disclosure provide solutions that allows for dynamic and controlled variation of speed and torque, adapting to various applications without the need to change the motor or use external devices like frequency converters. Further aspects of this disclosure improve the electric motor's energy efficiency across a wider range of operational conditions, reducing energy consumption and associated operational costs.

Aspects of this disclosure can further simplify the electric motor setup and reduce the dependence on external components, thereby reducing installation and maintenance costs. Aspects of this disclosure further provide more precise control and quicker response to variations in load conditions, enhancing the overall performance of the electric motor. This disclosure also relates to a more versatile and adaptable electric motor platform, capable of meeting a broader range of needs without extensive redesigns.

Further aspects of this disclosure can also decrease wear and degradation through more efficient and controlled operation, resulting in greater durability and reliability. In addition, aspects of this disclosure can cohesively integrate with advanced technologies to provide enhanced capabilities not possible with traditional electric motor designs.

These improvements and advantages can be implemented in a number of different applications and sectors. Examples of these in the automotive industry, include land vehicles of small and large scale. The electric motor described herein can provide flexibility in drivetrain design, enabling designers of electric and hybrid vehicles to optimize motors for a wide range of speeds and loads without compromising efficiency, offering an improved balance between acceleration and top speed. For example, the electric motor described herein is advantageous for direct installation in vehicle wheels without the need for a gearbox or multiplier. The electric motor described herein can also be used to reduce the number of components in various applications. For example, using the disclosed electric motor can reduce the need for complex transmissions or multiple motors to cover different speed and torque ranges, thus simplifying the drivetrain and potentially reducing weight and cost. The described technology can also provide an improvement to efficiency, for example, by adjusting the configuration of the poles of the electric motor to operate optimally at different speeds, a vehicle's energy efficiency can be improved, extending the battery range and reducing energy consumption. The described technology can also optimize motor efficiency for electric vehicles under different driving conditions, such as acceleration and cruising, thereby improving vehicle range and reducing energy consumption. In certain embodiments, the described electric motor is advantageous for direct installation in vehicle wheels without the need for a gearbox, multiplier, or reducer.

The described technology can also be advantageously applied to maritime vehicles. For example, the described electric motor can improve precision of speed control, which can be particularly useful in maritime applications where precise speed control can be beneficial for maneuvers and port operations. The described technology can offer finer control without additional systems. The electric motor according to aspects of this disclosure can also improve efficiency across the operating range, which is useful for maritime and aquatic vehicles which often operate across a wide range of load and speed conditions. The ability to vary the configuration of the poles can further improve motor performance for any condition, improving fuel efficiency and reducing emissions. The described electric motor is advantageous in hybrid and electric boats by providing the ability to adjust the motor to adapt to different sailing conditions which can significantly improve fuel efficiency and maneuverability.

Another application for the described technology is in electric generators. For example, the described electric motor can provide improved adaptability to renewable energy sources. In generators connected to renewable energy sources, such as wind or hydroelectric, the ability to change the configuration of an electric motor's poles can allow for more efficient adaptation to variations in wind speed or water flow, improving energy generation. The described technology can further provide improvements in energy quality, for example, by adjusting the generation speed to maintain a substantially constant output frequency under different loads, the quality of the generated energy can be improved, which can be important for sensitive applications and to meet electrical grid standards. In energy generation systems, such as wind or hydroelectric turbines, the described technology provides the ability to adapt the speed and torque of the electric generator which can increase energy conversion efficiency based on the variable conditions of wind or water. The described electric motor can also decrease manufacturing costs as it does not require a multiplier or reducer gearbox.